Skatebrake.com

ABSTRACT

An improved disk brake system which is readily adaptable to conventional small wheel vehicles such as: skateboards, scooters, rollerblades and carts which facilitates an improved heat management design to provided a higher performance of operation without brake failure thereby improving the safety of said vehicles. The disc brake  6  includes a friction pad disc  18  which is affixed to the central aperture of a wheel hub  28,  (FIG.  1 ) a matching non-turning rotor  24  that is slideably linked to a square hub  26  that is made apart of an axle support structure  17.  The non-turning rotor  24  becomes controllably coupled with the friction pad disc  18  by means of a cam lever  13,  which is pivotally attached to the axle support structure  17.  A means is provided for remotely activating the mechanism, which includes a Bowden cable  8,  wire  9  and handgrip  10.  The friction pad disc  18  provides for efficient braking action, smooth modulation while insulating wheel components from frictional heat associated with braking. The non-turning rotor  24  conduct frictional heat directly into axle support structure  17,  which provides for rapid dissipation of heat by means of air-cooling.

BACKGROUND OF INVENTION

[0001] The invention presented herein is a disc brake mechanism for small wheel vehicles that is uniquely designed to move heat generated during the braking process away from heat sensitive wheel components and into structure that will not be damaged by thermal loading. The brake is readily adaptable for vehicles such as scooters, skateboards, rollerblades and small carts using urethane or rubber wheels.

[0002] With the advent of the X games and Gravity games, rider's young and old are traveling faster than ever before on skateboards, scooters, rollerblades, carts and all-terrain vehicles, mostly unequipped with any form of brake device. The most popular small wheel brake today is found on the Razor scooter. The brake involves a fender formed of aluminum that is pushed onto the wheel surface by the rider. This simple brake works fine for small children riding at slow speeds, however, the brake becomes faulty when a rider weighing more than 120 pounds travels downhill and reaches a speed in excess of 10 miles per hour and tries to stop. When the rider pushes the fender onto the wheel surface frictional heat quickly exceeds 220 degrees F. and the wheel surface begins to melt, becomes slippery and the rider is subject to loosing control and crashing.

[0003] As for other small wheel vehicles such as skateboards or small carts there is no brake currently available to the industry. Rollerbladers still rely on a rubber drag brake located on the back heel of a skate. High-speed luge racers still drag their tennis shoes on the road surface to slow down. A quality brake system for small wheel vehicles has proven to be an elusive goal for inventors. There are problems associated with braking small wheels. The most serious problem for brake designers to over come is that of frictional heat associated with stopping an adult rider traveling at speeds in excess of 10-15 mph. Consider the following; a rider traveling 20 mph will require 4 times the braking force to slow or stop as he would traveling at 10 mph. The same rider traveling at 30 mph will require 9 times the braking force as he would at 10 mph. The rider traveling at 40 mph will require 16 times the braking force as he would at 10 mph. Heat build up in the brake F mechanism is directly proportional to the amount of force used to slow down or stop the vehicle.

[0004] In the past inventors have created several types of small wheel brake systems that apply friction directly to the wheel. This type of brake system is typical of U.S. Pat. No. 4,055,234, to Burton (1977), which uses friction members in direct contact with the ride surface of the wheel. This mechanism is effective at slowing a 100-pound rider at speed less than 10 mph over a short distance; however, the wheels are subject to melting when the brake is activated by an adult rider at a speed of 15 mph due to thermal loading at the wheel surface.

[0005] Another problem with current small wheel brake design is found in U.S. Pat. No. 2,953,389 to M. L Green (1960). The M. L. Green art offers a device that uses brake arms that includes a brake shoe which bears against the side of a wheel rim rather than against the tire mounted on the wheel in order to reduce tire wear. Frictional heat is not a design consideration or mentioned with the Green brake. Heat generated during the brake process is directed into the wheel hub, because the brake pad acts as a thermal insulator to the axle support structure. Component failure due to thermal loading at the wheel hub is to be expected by an adult rider.

[0006] Another problem with current small wheel brake designs is found in U.S. Pat. No. 4,076,266 to Krausz (1978). The Krausz art provides a structure that utilizes a piston to activate a pair of bars that seat friction materials at their ends, which bears against metal discs fitted to the rear wheels. This mechanism directs heat generated during operation into a steel disc attached to the wheel, which would result in melting temperatures when operated by an adult rider. Again, no consideration has been given to heat generated during brake operation.

[0007] While art mentioned above produce an adequate level of performance for a small rider at slow speeds, prior art has not addressed the problem of frictional heat associated with braking an adult rider traveling at speeds in excess of 10-15 miles per hour. The invention presented herein is uniquely designed to withstand braking forces associated with stopping an adult rider traveling at speeds up to 50 mph. The mechanism is further designed to conduct heat generated during the brake process away from heat sensitive wheel components and into structure that will not be damaged by thermal loading but provide for efficient convection of the stored heat. In addition, the mechanism provides for a means of insulating wheel components from heat, which would otherwise melt during operation.

OBJECT AND ADVANTAGES

[0008] The present invention is a disc brake that is readily adaptable for small wheel vehicles such as skateboards, scooters, rollerblades or small carts. The brake is uniquely designed to move heat generated during the brake process away from heat sensitive wheel components and into an axle support structure where it is safely dissipated into the air. This and other features enable the mechanism to operate in a reliable and predictable fashion for children and adult riders. Several objectives of the present invention are:

[0009] a) to provide a disc brake mechanism that effectively transforms kinetic energy from a rotating wheel into heat and then moves that heat to a place that will not be damaged by thermal loading;

[0010] b) to provide a disc brake mechanism with a means of supporting one wheel;

[0011] c) to provide a disc brake mechanism that will conduct heat generated during the braking process into an axle support structure;

[0012] d) to provide a disc brake mechanism that includes a friction pad disc affixed to the wheel hub;

[0013] e) to provide a disc brake mechanism that includes a non-tuning rotor and a matching friction pad disc;

[0014] f) to provide a disc brake mechanism whereby the non-turning rotor may controllably coupled with the friction pad disc by a variety of means including a cam lever, rotary screw, mechanical linkage or a hydraulic activator.

[0015] g) to provide a disc brake mechanism whereby a non-turning rotor may be mechanically linked to an axle support structure by a variety of means including: an irregular shaped shaft, or longitudinal splines, or a square hub or a keyed shaft thereby preventing the rotor from turning.

[0016] h) to provide a disc mechanism that may be activated by a variety of means including a Bowden cable and wire, or a hydraulic system or mechanical linkage;

[0017] i) to provide a disc brake mechanism with returns to a normally non-activated position;

[0018] j) to provide disc brake mechanism that is actuated by a foot or hand lever.

[0019] Further advantages of the modified disc brake mechanism include; the ability to retrofit common skateboard trucks, scooters, carts and rollerblades with a disc brake system that will provide riders of all sizes with a high level of safety and brake performance.

SUMMARY, RAMIFICATIONS AND SCOPE

[0020] The disc brake mechanism provided herein offers riders a new level of brake technology for small wheel vehicles that hereto now has not been available. The mechanism is designed with components that will produce and withstand braking forces associated with slowing or stopping an adult rider traveling at speeds in excess of 50 miles per hour. Frictional heat generated during the brake process is conducted away from heat sensitive wheel component and directed into the axle support structure where it is safely dissipated into the air.

[0021] A notable feature of the brake is the use and location of a friction pad disc, which is affixed to the central aperture of the wheel hub. Locating the friction pad disc on the wheel hub provides an unobstructed path for heat to naturally move into the non-turing rotor and axle support structure. Furthermore, the friction pad disc embodies other advantages in that it is porous and thereby adheres well to the wheel hub by an epoxy adhesive;

[0022] it is nonconductive, thereby providing thermal insulation for the wheel hub;

[0023] it is constructed of a durable, light weight, heat resistant material;

[0024] it provides for a large braking surface area;

[0025] it is designed to operate under conditions being imposed;

[0026] it spins with the wheel, which provides for added cooling;

[0027] it may be inset into the wheel hub making it unobtrusive;

[0028] it provides riders with a smooth brake modulation;

[0029] it is readily available in a variety of formulations and densities.

[0030] The mechanism has numerous advantages over prior art including; a natural heat management system which helps to maintain the integrity of the wheels. The large friction pad surface area provides for efficient, long lasting operation and smooth, predictable modulation for the rider. The brake has few moving parts, is compact by design and is cost effective to manufacture. The brake is readily adaptable to existing skateboard trucks, scooters, skates and carts. The mechanism may be operated as a stand-alone unit or may be connected to multiple disc brake assemblies with a simple Bowden cable and wire assembly.

[0031] The disc brake presented herein will provide sport enthusiast with a superior means of controlling and stopping their vehicles. There are many areas, roads, trails and slopes that are ideal for downhill entertainment but hereto now considered to be to dangerous to ride because of the degree of inclination. The brake presented herein will give riders speed control necessary to safely navigate and play in these areas for a great new form of entertainment.

[0032] Although the description above contains many specifics, these should not be construed as limiting the scope of the invention but as merely providing illustrations of some of the presently preferred embodiments of this invention.

BRIEF DESCRIPTION OF THE DRAWINGS

[0033]FIG. 1 is a side view of a skateboard with an embodiment of the disc brake mechanism.

[0034]FIG. 2 is a plan view of the disc brake mechanism.

[0035]FIG. 3 is a view from above showing the disc brake assembly in a non-actuated configuration.

[0036]FIG. 4 is a view from above showing the brake assembly in an actuated configuration, a pair of coaxial wheels.

REFERENCE NUMERALS IN DRAWINGS

[0037] Number Description Number Description 1 Conventional skateboard 2 Left side of mechanism 3 Right side of mechanism 4 Deck 5 Front truck 6 Dual acting disc brake 7 Wheel 8 Bowden cable 9 Wire 10 Handgrip 11 Spring 12 Arm extension 13 Cam lever 14 Pivot hinge 15 Attachment bolt 16 Square hub 17 Axle support structure 18 Friction pad disc 19 adhesive 20 Anti friction bearing 21 Axle 22 Nut 23 Mounting plate 24 Non-turning rotor 25 Cable stop 26 Wire attachment fastener 27 Wheel spacer 28 Wheel hub 29 Left disc brake 30 Right disc brake

DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0038] It is to be understood that the disc brake mechanism presented herein can be adapted for a variety of small wheel vehicles. For reason of explanation, a standard skateboard truck will be illustrated using a dual acting disc brake. Referring to FIG. 1, a conventional skateboard 1 is shown that includes: a deck 4, a front truck 5, a pair of coaxial wheels 7, a dual acting disc brake 6, fitted with a pair of coaxial wheels 7 and a means for the rider to remotely activate the brake using a Bowden cable system 8, and handgrip 10. The board operates, as does a standard skateboard with the exception that the rider holds a hand lever 10 to remotely activate the brake 6 when desiring to slow down or stop. In FIG. 3 the dual acting disc brake 6 is shown in a normally non-actuated configuration. Wheel 7, which includes a friction pad disc 18, spins freely from non-turning rotors in this configuration. In FIG. 4 the dual acting disc brake 6 is shown in an activated configuration. A rider activates the brake 6 by squeezing the handgrip 10, which draws a wire 9 into the cable sheath 8. This action causes cam levers 13 to be pulled together at pivot hinge 14 providing an equal leveraged force upon slideable, non-tuning rotors 24. This action provides riders with a smooth and effective braking action. The spring 11 returns and maintains the mechanism in a normally non-actuated configuration as illustrated in FIG. 3. In FIG. 2, the dual action disc brake mechanism 6 is shown in a non-activated configuration. Each disc brake mechanism 29, 30 include a hub 16, which is made apart of an axle support structure 17. The hub 16 provides a means for mechanically linking the non-turning rotor 24 to the axle support structure 17 while allowing for slideable movement of the non-turning rotor 24. There are a variety of means for linking the non-turning rotor 24 to the axle support structure 17 including: a square hub 16 shown, or a splined shaft, or a irregular shaped shaft not shown. The square hub 16 is located on each end of the axle support structure 17 at the central aperture of the axle 21. The non-turning rotor 24 includes first a borehole matching that of the square hub 16, at its central aperture, thus providing a slideable, linked movement along the square hub 16. In addition, the non-turning rotor, or section thereof 24 is formed to match the diameter of the friction pad disc 18. This provides for improved efficiency, modulation and heat conduction during brake operation. Additional cooling may provide to the disc brake 6 by drilling a series of holes in the non-tuning rotor 24 face providing for added ventilation. The non-turning rotor 24 may be leveraged into the friction pad disk by a variety of means including a cam lever 13 shown, or a rotary screw, or a hydraulic actuator, or mechanical linkage not shown. The cam lever 13 is pivotally attached to hub 16 by an attachment bolt 15 and pivot hinge 14, which is attached to one side of hub 16. The cam lever 13 is forked at one end to provide equilateral pressure on the non-turning rotor 24 when activated by the rider. The cam lever 13 provides a leverage force on the non-turning rotor 24 causing it to become controllably engaged with the friction pad disc 18 and wheel 7. The other end of cam lever 13 is provided with a means for connecting an arm extension 12 or cable wire 9. Extending or reducing the length of the cam lever 13 will adjust leverage force available to riders.

[0039] Extending out from each end of the axle support structure 17 is a wheel-bearing axle 21. The axle supports a wheel assembly which includes a wheel hub 28, wheel 7, anti friction bearings 20, bearing spacer 27, and friction pad disc 18 which is affixed to the central aperture of wheel hub 28. The friction pad disc 18 is formed of a commercial grade friction material and may be affixed using an epoxy adhesive 19 common to the automotive industry. Additional cooling may be provided to the mechanism by forming the wheel hub 28 into a fan shape, which would draw air into the device when operating.

[0040] The mechanism may be activated by a variety of means including a Bowden cable 8 and wire 6 as shown, a hydraulic system or a mechanical linkage system not shown. Referring now to the cable system shown, a cable assembly 8 of the type having an outer sheath with a sliding Bowden wire cable 9, which is operated by means of a handgrip 10, (FIG. 1) which causes a wire 9, to be retracted into the sheath 8 when handgrip 10 is squeezed. The sheath terminates at cable stop 25, which is made apart of arm extension 12. The arm extension 12 is attached to cam lever 13 by attachment bolt 15. The cable wire 9 passes threw a bore in the cable stop 25, a spring 11, and a bore in wire attachment fastener 26, securing the cable to cam lever 13.

[0041] When activated, the cam lever 13 applies equilateral pressure against the non-tuning rotors 24 causing them to become controllably coupled with friction pad discs 18 and wheel hub 28, anti friction bearings 20, spacers 27 and nuts 22. The wheel 7 assemblies are firmly secured to the axle support structure by nuts 22 located at each end of the axle. The axle support structure 17, which includes square hubs 16, non-turning rotors 24, and the mounting plates 23 resists rotational forces generated from the friction pad discs 18 spinning wheels 7 and any given load. The friction pad discs 18 are made from a non-conductive material and are therefore less conductive than the non-turning rotors 24. Therefore, heat generated during the brake process is naturally drawn away from the wheels and into the very conductive axle support structure 17 where it is dissipated into the passing air. A further level of insulation and heat dissipation is provided by the spinning wheels.

[0042] Without proper heat management, urethane wheels are subject to melting and brake failure after a period of only a few minutes of operation. The mechanism described herein will maintain operational integrity under constant use by an adult rider at speeds in excess of 50 mile per hour. 

I claim:
 1. A disc brake mechanism for small-wheeled vehicles comprised of a. a carriage that has wheels mounted thereunder that rotate freely and independent of one another so that the carriage can roll upon a surface; b. wherein a friction pad disc is affixed to the central aperture of a wheel hub and rotates with said wheels; c. wherein a non-turning rotor is controllably coupled with the friction pad disc and wheel assembly providing braking action; d. wherein a means is provided for controlling coupled rotational energy from said wheels to an axle support structure, which is mounted to the carriage; e. wherein a means is provided to exert an equilateral force upon slideable non-turning rotor; f. wherein a means is provided to remotely actuate the brake mechanism; g. wherein a spring is used to maintain the mechanism in a normally non-activated configuration.
 2. A disc brake mechanism as recited in claim 1 wherein: the non-turning rotor or segment thereof is formed to match the friction pad disc.
 3. A disk brake mechanism as recited in claim 1 wherein: the non-turning rotor is slideably linked to the axle support structure by a variety of means including a square hub, or a splined shaft, or an irregular shaped shaft.
 4. A disc brake mechanism as recited in claim 1 wherein: said non-turning rotor has a central aperture or borehole having a mechanical link to provide slideable movement along the axle support structure.
 5. A disc brake mechanism as recited in claim 1 wherein: the non-turning rotor is slideably coupled with the friction pad disc by a variety of means including a cam lever, or a rotary screw, or a hydraulic actuator, or mechanical linkage.
 6. A disc brake mechanism as recited in claim 1 wherein: the brake mechanism is activated by a variety of means including: a Bowden cable assembly, hydraulic system or mechanical link initiated by a handgrip or foot activation.
 7. A disc brake mechanism as recited in claim 1 wherein: said friction pad disc provides thermal insulation for wheel components.
 8. A disc brake mechanism as recited in claim 1 wherein: said non-turning rotor conducts frictional heat directly into the axle support structure providing rapid dissipation of heat by means of air cooling over the surface area of the axle support structure. 